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BMW K 1100 LT, Repair Manual

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BMW K 1100 LT Repair Manual Download Page 175

23.1

Contents

Page

23

Technical Data

............................................................................................................................... 3

Removing transmission (gearbox) 

......................................................................................5

Preparatory work

 .............................................................................................................................5

Removing starter

 .............................................................................................................................6

Removing bearing mount with main stand

 ..........................................................................7

Removing transmission (gearbox)

 ...........................................................................................8

Disassembling transmission (gearbox) 

............................................................................9

Removing transmission cover.

 ..................................................................................................9

Disassembling/assembling transmission cover

 ..............................................................10

Removing and installing bearing shell ................................................................................................10
Removing and installing shaft sealing ring on input shaft ...................................................................10
Removing and installing locking lever  ................................................................................................10

Removing gear selector drum

 .................................................................................................11

Removing gearshift forks

 ...........................................................................................................11

Removing transmission shafts

 ................................................................................................12

Removing pawl

 ...............................................................................................................................12

Removing selector shaft

 ............................................................................................................13

Removing segment

 ......................................................................................................................13

Removing and installing shaft sealing ring on input shaft

 ...........................................13

Removing and installing shaft sealing ring for gear selector drum

 .........................14

Removing and installing bearing shell for taper roller bearing on input shaft

 ....14

Removing and installing ball bearing on intermediate shaft

 ......................................14

Disassembling and assembling input shaft

 .......................................................................15

Disassembling input shaft  .................................................................................................................15
Assembling input shaft  ......................................................................................................................15

23 Gearbox

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Summary of Contents for K 1100 LT

Page 1: ...BMW AG Motorcycle Division After Sales K 1100 LT RS Repair Manual Downloaded from www Manualslib com manuals search engine...

Page 2: ...rights reserved Not to be reprinted translated or duplicated either wholly or in part without prior written permission Errors and omissions excepted subject to technical amendment Produced in Germany...

Page 3: ...is repeated in the work descriptions which follow so that work can take place without interruption Use of the BMW special tools needed for certain tasks is described in the work instructions If the n...

Page 4: ...ion on operating inspecting and adjusting work for the motorcycle as well as maintenance procedures eCaution Instructions and precautions specifically intended to prevent damage to the motorcycle Fail...

Page 5: ...ry 8 5 Check steering head bearing play adjust if necessary Check battery acid level top up with distilled water if necessary Clean and grease the battery posts if necessary Take up slack at bolts and...

Page 6: ...s keys optional extras Check front and rear wheel brake fluid levels only disc brake Check switch function of electrically operated side stand angle Check torque setting of the rear wheel retaining st...

Page 7: ...electrics 12 1 13 Fuel preparation and control 13 1 16 Fuel tank and lines 16 1 17 Radiator 17 1 18 Exhaust system 18 1 21 Clutch 21 1 23 Gearbox 23 1 31 Front fork 31 1 32 Steering 32 1 Contents Gro...

Page 8: ...33 1 34 Brakes 34 1 36 Wheels and tyres 36 1 46 Frame 46 1 51 Equipment 51 1 61 General electrical equipment 61 1 62 Instruments 62 1 63 Lights 63 1 Group Chapter Downloaded from www Manualslib com ma...

Page 9: ...pulse generator at rear wheel drive 13 Inspections I III IV Checking brake pads brake discs for wear and renewing if necessary 14 Inspection II III Front wheel brake Rear wheel brake Checking brake f...

Page 10: ...Checking valve clearance and adjusting if necessary 20 Inspections I III Adjusting valve clearance 20 Removing sprockets Removing camshafts Installing camshafts Installing sprockets Installing cylind...

Page 11: ...at crankshaft 50 Main bearing cap to crankcase 50 Connecting rod Big end cap Wrench angle 80 30 Input shaft Front bearing 18 Rear bearing 40 Engine block Crankshaft cover 9 Lower part outer 10 Oil sum...

Page 12: ...rter motor to gearbox 9 Mixture preparation Intake stub pipe 9 Fuel injection rail 9 Cooling system Coolant stub pipe at cylinder head 9 Temperature sensor at coolant stub pipe 30 Air cleaner Lower pa...

Page 13: ...h Loctite 243 Temperature sensor to coolant stub pipe 30 18 Exhaust System Exhaust system to cylinder head 21 Front silencer muffler 12 Exhaust system holder to footrest plate 33 Exhaust system to hol...

Page 14: ...ite 2701 Bearing pin loose bearing rear wheel drive in swinging arm 7 clean thread Loctite 2701 Locknut loose bearing rear wheel drive in swinging arm 105 clean thread Loctite 2701 Suspension strut to...

Page 15: ...earing rear wheel drive in swinging arm 150 clean thread Loctite 2701 Bearing pin loose bearing rear wheel drive in swinging arm 7 clean thread Loctite 2701 Locknut loose bearing rear wheel drive in s...

Page 16: ...Distributor to fork bridge 6 Brake caliperto sliding tube rear wheel drive 9 ABS unit to mounting 9 Bleed screw at ABS unit 9 Master brake cylinder to foot rest plate 9 Mounting pin to handbrake leve...

Page 17: ...nut 65 Centre stand to bearing block 41 Side stand to bearing block 41 Footrest plate 15 Brake line to handbrake cylinder 11 Brake line to distributor 11 51 Equipment Handlebar clamping blocks 22 She...

Page 18: ...lastic sealant 81 22 9 400 339 100 g tube Adhesives and retaining agents Loctite 648 Surface sealant narrow gap 07 58 9 067 732 5 g bottle Loctite 638 Surface sealant wide gap 07 58 9 056 030 10 ml bo...

Page 19: ...note of hint at filter Replace O ring in cover if necessary X Tightening torques Oil drain plug 18 Nm Cover to oil sump 6 Nm Quantities Oil content 3 50 l 6 16 Imp pt Oil content with filter change 3...

Page 20: ...Note The load on the front wheel must be relieved to en sure as much air as possible flows in before the fixed tubes are closed off with the filler plugs so as to provide additional damping Fill with...

Page 21: ...t line to pump Install in the reverse order of removal L Note Gasket 2 must not close off the overflow hole En sure recesses arrows in gasket are fitted in correct position Cleaning inductive pulse ge...

Page 22: ...te sets Min pad thickness on carrier plate 1 5 mm 0 06 in Install in the reverse order of removal L Note Before installing the brake caliper completely press back pistons with resetting tool 1 BMW No...

Page 23: ...g ATE SL brake fluid Checking brake system Inspection III Check all brake lines for damage and ensure they are fitted in the correct position Wipe clean all screw connections of the brake lines Opera...

Page 24: ...re is felt to build up Hold the handbrake lever in to maintain the braking pressure and open the bleed screw at the same time pulling the hanbrake lever up firmly eCaution Do not release the handbrake...

Page 25: ...a 95 mm 3 74 in b 50 mm 1 97 in Fold in side stand and start engine Slowly fold out side stand the engine must stall in the area of dimension b If the engine does not stall the switch must be checked...

Page 26: ...turns then screw in until pressure can be felt Lock adjusting screw with locknut Set dimension A with adjusting screw at clutch hand lever Lock adjusting screw 5 with knurled nut 3 Dimension A 4 0 5 m...

Page 27: ...cquer and must not be reset L Note Stop face 1 must make contact with screw 2 and the wire cable must have zero play failing this cable play must be adjusted Check stop face 1 Move the increased start...

Page 28: ...linder No 1 timing end to ignition TDC The setting device for the camshafts BMW No 11 3 700 must fit in the slots at the ends of the shafts Unscrew screw plug in chain case cover Lock chain tensioner...

Page 29: ...ertically with respect to the cylinder head The grooves at the front end must face the inside towards the crankshaft Fit setting device BMW No 11 3 700 and se cure to the bearings of the camshaft Inst...

Page 30: ...d the crescent areas in the cover with oil to facilitate installation Apply a little 3 bond 1209 in the joint area at the top and bottom chain case cover cylinder head surfaces free of grease Fit cyli...

Page 31: ...tting torque Hexagon nut 12 Nm New bearing Pretighten hexagon nut to 25 Nm Move steering several times from stop to stop loosen hexagon nut and retighten 12 Nm Mark new position of setting ring on adh...

Page 32: ...de pins adjustable screen Inspections III IV Release retaining screw 1 on both sides Slightly raise plate 2 Spray guide pins 3 with silicone spray LT000260 2 1 3 3 Downloaded from www Manualslib com m...

Page 33: ...es if not already warm eCaution Max idling time at a standstill 20 minutes Run the engine at idle speed Select bar diagram display with maximum resolution L Note If the differences between the individ...

Page 34: ...a richer mixture the CO value will rise towards its maximum value Turning further in direction 1 will not vary the CO value any further Turn in direction 3 for a leaner mixture the CO val ue will dro...

Page 35: ...aring 18 Removing timing chain cover 19 Removing the Hall effect signal transmitter 19 Remove the crankshaft cover 19 Removing cylinder head cover 19 Removing and installing sealing ring in timing cas...

Page 36: ...ler 30 Removing output shaft 31 Removing oil sump 31 Removing oil filter 31 Removing lower section of crankcase 31 Removing and installing oil level sight glass 31 Stripping and assembling output shaf...

Page 37: ...g intermediate flange 46 Installing driver 46 Installing alternator 46 Installing timing case cover 47 Installing hall effect transmitter 47 Installing cover for Hall effect transmitter 48 Installing...

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Page 39: ...0 Permissible continuous engine speed min 1 8500 Idle speed min 1 950 50 Direction of rotation Anti clockwise looking at ignition system Compression test pressure bar psi good above 10 0 142 3 normal...

Page 40: ...in 22 95 0 886 Stem dia Inlet mm in 5 96 5 975 0 2346 0 2352 Wear limit mm in 5 94 0 2339 Exhaust mm in 5 945 5 96 0 2341 0 2346 Wear limit mm in 5 925 0 2333 Valve head edge thickness Inlet mm in 1...

Page 41: ...earing dia mm in 29 970 24 0 1 180 0 945 Wear limit mm in 29 95 1 179 Guide bearing bore mm in 30 02 30 041 1 1819 1 1827 Camshaft bearing bore mm in 24 02 24 041 0 945 0 9465 Radial clearance Guide b...

Page 42: ...1 6142 1 6148 Wide big end bearing mm in 21 973 22 025 0 8651 0 8671 Big end bearing endplay mm in 0 130 0 312 0 0051 0 0123 Wear limit mm in 0 400 0 0157 Piston pin bore dia mm in 20 000 20 021 0 78...

Page 43: ...fer ring with tubular spring Height mm in 2 475 2 490 0 0974 0 0980 Gap mm in 0 20 0 45 0 0079 0 0177 Wear limit mm in 1 50 0 0591 Side clearance mm in 0 020 0 055 0 0008 0 0022 Wear limit mm in 0 30...

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Page 45: ...ning at the battery carrier Remove the left footrest plate Remove the right footrest plate together with the brake line and master brake cylinder Detach the engine wiring harness Separate the plug con...

Page 46: ...rail Remove throttle rail Attach engine mount BMW No 11 0 610 to the engine block Lower the hoist and support the engine on as sembly stand BMW No 00 1 490 Remove the hoist Drain the oil LT110050 LT11...

Page 47: ...ediate flange Remove alternator Remove coils with holder Removing driver To remove the screw support the driver arrow Pull the driver off by hand LT110070 LT110080 Downloaded from www Manualslib com m...

Page 48: ...sh O ring 3 forwards with the clutch housing and remove with a hook Pull out clutch housing 4 noting the presence of thrust washer 5 1 2 3 4 5 LT110090 LT110100 11 2 800 If necessary pull the clutch h...

Page 49: ...g Heat the intermediate flange at the bearing seat to 120 C Press the ball bearing in as far as the Seeger cir clip 4 3 2 1 j 120 LT110120 Insert the cup spring with the larger diameter fac ing the be...

Page 50: ...an internal puller BMW No 00 5 010 and pressure head Pre shape the sealing ring which must be dry with the thumb and drive it in with drift BMW No 11 1 620 and handle BMW No 00 5 500 Removing counter...

Page 51: ...ut cup spring 4 Pull needle roller bearing 6 out of the freewheel gear with counter holder BMW No 00 8 570 and internal puller 21 3 BMW No 00 8 574 1 2 3 4 5 6 LT110160 LT110170 00 8 574 00 8 570 Asse...

Page 52: ...and O ring on to the lay shaft Removing and installing layshaft nee dle roller bearing Removing bearing Heat the bearing seat to 100 C Pull out the bearing with counter support BMW No 00 8 570 and int...

Page 53: ...te rotor 4 and take off adjusting washer 5 Remove the crankshaft cover Detach the coolant hose at the water pump and radiator Remove the cover Removing cylinder head cover Remove the ignition leads Re...

Page 54: ...the marking on the housing Removing chain tensioner Secure chain tensioner 1 with clamp BMW No 11 5 500 arrow and remove it 3 2 1 4 LT110230 11 5 500 1 LT110240 Removing chain tensioner rail Remove cl...

Page 55: ...2 3 LT110260 1 LT110250 Removing chain guide Remove keepers 2 and washers 3 at the pivot pins Raise chain guide 4 slightly at the cylinder head and press it down again The toothed washer with eccentri...

Page 56: ...t the camshafts Removing cylinder head Unscrew the cylinder head bolts 3 with Torx in sert BMW No 00 2 610 Strike the cylinder head lightly with a plastic faced hammer to dislodge it Removing bucket t...

Page 57: ...lease valve spring 3 and remove the various components Upper spring plate 2 lower spring plate 4 Pull out the valve stem seal with pliers BMW No 11 1 250 Remachining valve seat D valve diameter B valv...

Page 58: ...stem Drive in sealing ring 1 with drift BMW No 11 5 601 until the drift reaches the cylinder head eCaution Remember to remove the assembly sleeve from the valve stem Insert the valve spring Install th...

Page 59: ...ence at cylinders 2 and 3 Removing main bearings Take out all main bearing bolts except one ar row Take off the bearing caps Take out the last bolt Take off the bearing cap pressing the crankshaft in...

Page 60: ...11 2 930 Carefully remove piston rings 3 Clean the piston 1 3 1 2 LT110350 Checking piston dimensions Measure piston diameter with a micrometer at distance A Make Dimension A KS 12 0 mm 0 472 in Mahl...

Page 61: ...ern in the direction of forward travel and at a right angle to it Removing and installing small end bushing Press out the small end bushing The gap in the new bushing when pressed in must be at an ang...

Page 62: ...od eye is on top in the in stalled position The arrow marking on the piston crown must point in the forward travel direction Install only pistons of the same make and the same weight category eCaution...

Page 63: ...aced hammer Remove the housing and loosen the gasket with light blows of a plastic faced hammer Pull off the housing Dismantling pump Clamp the pump housing into a vise at the seal ing faces using sof...

Page 64: ...m 7 9 11 10 12 13 14 6 5 15 16 LT110432 Install the shaft sealing ring and slipring seal Drive in sealing ring 5 from the water side with the open side downwards using drift BMW No 11 1 640 and handle...

Page 65: ...lows of a plastic faced hammer loos en the gasket and take off the lower section of the housing Note presence of O rings Carefully lift out the output shaft the needle roller bearing and circlip are l...

Page 66: ...Clamp the damper housing into a vise with soft jaws to take the load off circlip 7 7 8 9 10 11 6 5 1 2 3 4 LT110450 7 LT110460 Remove circlip 7 with Seeger circlip pliers Using two arm puller BMW No...

Page 67: ...Heat the ball bearing to 80 C and install it with shoulder upwards Clamp the damper housing and the ball bearing together in the vice with soft jaws Place the circlip arrow in the groove in front of...

Page 68: ...ut shaft Push circlip 1 and needle roller sleeve 2 on to the bearing point Place the output shaft in the crankcase L Note Gap of circlip 1 in crankcase arrow 1 2 LT110510 1 KR110521 Downloaded from ww...

Page 69: ...ng 4 40 Nm Needle roller bearing 5 18 Nm Retaining screws of two halves of the housing7 Nm 1 2 3 4 5 LT110530 6 7 KR110521 Installing oil mesh strainer Note presence of O ring 2 Installing oil filter...

Page 70: ...to be measured Take off the bearing cap Turn the crankshaft further by approximately an other 30 Wipe off oil at the bearing journal and bearing shell Measure bearing play with Plastigage Type Pg 1 BM...

Page 71: ...3 mm 0 0031 0 0072 in Wear limit 0 250 mm 0 0098 in Checking dimensions of crankshaft If measured bearing play was too large the di mensions of the crankshaft must be checked Regrinding stages 0 and 1...

Page 72: ...h the grooves aligned L Note Bearing caps 1 3 are marked for identification bearing caps 4 thrust bearing and 5 are not marked Tighten the bearings in the order shown starting from the centre and work...

Page 73: ...piston skirt and cylinder wall thoroughly LT110590 Using tensioning strap BMW No 11 2 925 com press the piston rings Insert the piston with conrod into the cylinder Drive the piston carefully into the...

Page 74: ...12 0 0026 in Wear limit 0 130 mm 0 0051 in If bearing shells are renewed note paint marks on crankpin and on big end bearing Regrinding stages 0 and 1 are available the crankpins are marked with a cor...

Page 75: ...o centre the gearwheels at the same time gradually tighten ing the retaining screws Tighten the retaining screws fully X Tightening torque Pump housing to crankcase 7 Nm Insert the wire for the oil pr...

Page 76: ...r head in position and insert bolts 1 with washers 2 as far as possible Tighten the cylinder head bolts in the order shown X Tightening torque Cylinder head bolts 20 Nm Attach tighten angle measuring...

Page 77: ...re also marked Inlet side odd numbers Exhaust side even numbers The numbers increase from the front timing end to the rear Oil the camshafts at their bearing points Tighten the bearing caps uniformly...

Page 78: ...the lower pivot pin 2 with the washer and clip Install chain sprocket 3 for the inlet camshaft so that the timing chain is pulled taut towards the guide rail Insert the retaining screw as far as possi...

Page 79: ...ove the special tool Tighten the chain sprockets holding the hexa gon on the camshaft to prevent it from turning X Tightening torque Chain sprocket 54 Nm Checking valve clearances Turn the engine over...

Page 80: ...coat of 3 Bond 1209 to the sealing faces which must be free from oil and grease Attach the intermediate flange with all collets in position Tighten screws with Torx insert BMW No 00 2 600 X Tightenin...

Page 81: ...ht en it X Tightening torque Timing case cover 7 Nm Installing hall effect transmitter Screw adjusting disc 1 and gate rotor 2 to the crankshaft X Tightening torque Gate rotor 2 5 Nm Insert baseplate...

Page 82: ...effect transmitter with rubber grommet arrow in the timing case cover Secure the wire for the oil pressure telltale and coolant temperature with clip 1 Install cover with cork gasket X Tightening torq...

Page 83: ...and half moons lightly Press in the half moon on the gearbox side first Apply a small amount of 3 Bond 1209 to the joint area of the cylinder head and timing case cover Attach the cylinder head cover...

Page 84: ...Gearbox to intermediate flange 16 Nm Bolt the engine and frame together in the order stated here 1 Insert all 5 bolts loosely but do not screw them fully in Insert a 1 mm thick spacing washer at the...

Page 85: ...tle cable play 0 75 mm 0 03 in Install the radiator Install the left engine bulkhead 1 Attach cable strap 2 Install fuel line 3 Install right engine bulkhead 4 Attach cable strap 5 Install coolant lin...

Page 86: ...ing valve clearances The camshaft must be removed before the buck et tappets can be renewed Set cylinder 1 timing end to top dead centre on the ignition stroke The adjusting device for the camshafts B...

Page 87: ...istance between phase outputs 13 Checking stator winding for short to earth 13 Alternator LT from 1992 model year on RS 14 Checking alternator 15 Checking armature for short to earth 15 Removing and i...

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Page 89: ...ru 12R 5 DU Electrode gap mm in 0 6 0 2362 0 1 0 0039 wear limit 0 9 0 0354 Thread metric M 12 x 1 25 Ignition Ignition system Motronic mapped ignition timing control Ignition pulse triggert Two magne...

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Page 91: ...gasket 3 Remove base plate 4 Remove rotor 5 and setting plate 6 L Note Mark installation position of setting plate on engine case or remove in TDC position Install in the reverse order of removal L N...

Page 92: ...connect spark plug connector with flat nose pliers Unscrew spark plugs with spark plug box span ner BMW No 12 3 500 Screw dial gauge with extension 1 BMW No 00 2 580 into cylinder No 1 Set piston to T...

Page 93: ...ion Turn to right Advance ignition Firmly tighten base plate Check ignition timing Crank engine in normal direction The diode on the ignition setting device must go out at piston position 0 24 0 00945...

Page 94: ...connector 4 for terminal 1 and 15 Release earth ground connection 5 on starter Release top and bottom mounting at intermedi ate flange 6 Install in the reverse order of removal L Note Note assignment...

Page 95: ...move ignition coils Remove ignition output stage 1 Press retaining clip 2 and detach ignition output stage Install in the reverse order of removal L Note Before installing the ignition output stage co...

Page 96: ...move Motronic control unit ABS I Remove ABS control unit Remove battery Remove cover 1 Disconnect plug 2 Remove alternator Install in the reverse order of removal X Tightening torque Alternator 22 Nm...

Page 97: ...ol 3 BMW No 12 4 600 Pull off fan wheel 4 Remove key 5 Release retaining screw 6 for bearing end plate Clamp alternator in vice with jaw guards Remove bearing end plate 7 with three point puller BMW N...

Page 98: ...all in the reverse order of removal L Note During assembly insulate the solder points on the diode plate with silicone Coat bearing seat in hous ing with Molykote paste Checking exciter winding Using...

Page 99: ...ck resistance between each pair of outputs 1 2 1 3 2 3 Nominal resistance 0 6 The winding is in perfect working order at measured values below 1 0 Checking stator winding for short to earth Check wind...

Page 100: ...clips 2 and take off cover Remove voltage regulator 3 Remove coupling housing 4 using counter holder BMW No 12 4 600 Assemble in the reverse order of work X Tightening torque Coupling housing 50 Nm L...

Page 101: ...ress the key until the digital display shows 0 00 Using BMW diagnostic tester BMW No 61 1 510 measure the resistance be tween the sliprings Measured result 3 Checking armature for short to earth Measu...

Page 102: ...y carrier Release earth ground connection 1 at starter Release positive lead at starter Release second retaining screw 3 Pull out starter towards rear Install in the reverse order of removal L Note AB...

Page 103: ...ter at retaining lugs in vice with jaw guards Release retaining bolts 1 Detach bearing cap 2 Check seal 3 and O ring 4 Pull out armature 5 Note spacer washer 6 Check O ring 10 LT120160 2 3 4 5 6 1 Dow...

Page 104: ...g and installing brush holder 1 Hexagon nut 2 Outer insulator 3 Carbon brush holder 4 Brush retaining plate 5 O ring 6 Inner insulator LT120170 5 1 4 3 6 2 Downloaded from www Manualslib com manuals s...

Page 105: ...s With the aid of a small screwdriver lift spring 1 and pull out carbon brush L Note Fit carbon brush so that the chamfered side arrow faces towards the spring LT120180 1 Downloaded from www Manualsli...

Page 106: ...does not have its full capacity Note down value if measured value is above 8 Volt Connect voltmeter between positive and nega tive lead at starter Operate starter for 2 3 seconds Read off measured va...

Page 107: ...hing noise can be heard Check resistance if clear switching noise can be heard Checking starter relay with ohmmeter Connect positive lead from measuring instru ment to terminal 30 negative lead to ter...

Page 108: ...es Battery produces excessive gas vapour no Check contact between regulator alternator and between alternator diode carrier Is contact poor yes Repair cable connections no Check regulator Is regulator...

Page 109: ...efective yes Renew regulator no Check carbon brushes Are carbon brushes defective yes Renew carbon brushes no Check rectifier Is rectifier diode defective does rectifier diode have short to earth grou...

Page 110: ...arbon brushes defective yes Renew carbon brushes no Check rotor winding Is rotor winding defective yes Replace rotor no Check exiter current circuit Is exiter current circuit broken yes Repair break r...

Page 111: ...es Immediately disconnect charge line discharge when stationary Repair alternator no Check cable Is cable loose damaged yes Secure connections renew cable no Check regulator Is regulator defective yes...

Page 112: ...t switch is operated no Switch on light Does light operate no Check battery Is battery discharged defective yes Charge or renew battery no Check power circuit Does power circuit have a break yes Repai...

Page 113: ...supply line Is ignition switch defective yes no Replace ignition switch yes Is there a break in supply line yes Repair break no Check carbon brushes Are carbon brushes too short yes Replace carbon br...

Page 114: ...ure connections no Check collector Is collector dirty yes Clean collector no Check armature winding Is armature winding defective yes Repair starter Starter turns at high speed Engine stops or turns o...

Page 115: ...d between alternator diode carrier Is contact poor yes Repair cable connections no Check regulator Is regulator defective yes Renew regulator Acid level too low no Check level Is level below set level...

Page 116: ...ot charge correctly yes Check generator regulator replace if neces sary Acid leak at plugs no Check acid level Is acid level too high yes Adjust acid level no Check charging voltage Is charging voltag...

Page 117: ...distilled water no Check charge status Is charge too low yes Charge battery replace defective battery Battery constantly overcharged no Check charging system Is there a defect in charging system yes G...

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Page 119: ...8 Removing and installing throttle position sensor 8 Checking trottle position sensor 8 Adjusting throttle position sensor 8 Removing and installing air cleaner insert 9 Removing and installing air cl...

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Page 121: ...13 3 13 Technical data K 1100 LS K 1100 RS Inside of throttle stub pipe mm in 35 1 37795 CO value by vol 1 5 0 5 Idle speed rpm 950 50 Downloaded from www Manualslib com manuals search engine...

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Page 123: ...n 20 minutes at a standstill Run the engine at idle speed Select bar diagram and maximum resolution L Note If the differences between the individual columns are too great more than 2 5 mm 0 07874 0 19...

Page 124: ...face 1 must be in contact with screw 2 and the cable must have no play if this is not the case play at the cable must be adjusted Check stop face 1 Adjusting start speed increase Set speed increase t...

Page 125: ...direction 1 for a richer mixture the CO value will rise to a maximum Turning further in direction 1 has no effect on the CO value Turn in direction 3 for a leaner mixture the CO val ue will drop to a...

Page 126: ...cabinet up to the detent position Switch on the ignition MA 2 1 If the temperature warning light comes on the throttle position sensor is correctly adjust ed MA 2 1 If the temperature warning light d...

Page 127: ...t insulating bulkhead Release front clip 1 and both rear clips 2 Slightly raise top section of air cleaner housing and remove air cleaner element L Note Note installed position of air cleaner element...

Page 128: ...intake air guide Remove fairing retaining bracket on right Remove air cleaner Loosen wire retainer 1 disconnect multiplug 2 at air temperature sensor Release hose clips 3 at the air intake lines Loose...

Page 129: ...ection of air cleaner housing 7 out to the right Remove bottom section of air cleaner housing Install in the reverse order of removal X Tightening torques Bottom section of air cleaner housing 21 Nm I...

Page 130: ...h throttle cable 3 Detach operating cable 4 for start speed in crease Release hose clips at the air intake lines loosen at the throttle coupling Remove throttle rail from stub pipe Pull air return pip...

Page 131: ...the injector and pull it out Install in the reverse order of removal L Note Ensure that the O ring on the injector is in good con dition Removing and installing intake stub pipe X Tightening torque In...

Page 132: ...ound lead at battery Release multiplug 1 and disconnect Detach Motronic control unit 2 L Note Take particular care when connecting the multiplug to ensure the lock engages X Tightening torque Control...

Page 133: ...installing fuel tank 5 Removing and installing fuel filter 6 Removing and installing fuel level sensor 7 Removing and installing fuel pump 8 Checking fuel pump pressure 9 16 Fuel tank and lines Downl...

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Page 135: ...ank capacity l Imp gal 22 4 84 incl reserve capacity l Imp gal 5 1 1 Fuel pump Type Roller cell pump Make Bosch Operating voltage V 12 Fuel pressure bar psi 2 5 36 26 Delivery rate l h gal h 45 9 9 Do...

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Page 137: ...Release fuel line 2 at fuel tank Release fuel line 3 at injector rail Disconnect plug 4 Lift out fuel tank Install in the reverse order of removal L Note To facilitate installation coat rubber sleeve...

Page 138: ...Disconnect line and pull filter with line out of the fuel tank Change fuel filter L Note Note direction of fuel flow on filter Reconnect line to pump Install in the reverse order of removal L Note Ga...

Page 139: ...at the fuel pump Pull back insulation a little and remove fuel level pickup 3 from the outside Install in the reverse order of removal L Note Note installation location of gasket 4 Check that the leve...

Page 140: ...in the reverse order of removal L Note The rubber metal unit must be felt to engage on the fuel pump Note position of marking on rubber metal unit and filter with respect to each other Electrical conn...

Page 141: ...e gauge BMW No 16 1 500 on the delivery side Run engine at idle speed Fuel pressure Nominal value 2 5 bar 36 26 psi If the fuel pressure is lower check pump fuel fil ter and line LT160050 16 1 500 Dow...

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Page 143: ...thermostat 6 Checking thermostat 6 Removing and installing radiator 7 Removing and installing fan 8 Removing and installing coolant hoses 9 Checking cooling system 10 Checking cap for filler neck 10 C...

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Page 145: ...8 C 40 60 Only use nitride free long term frost and corro sion protection agents Thermostat opens at C 85 Cut in temperature for fan C 105 Cut in temperature for coolant warning lamp C 115 Pressure re...

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Page 147: ...ain plug temperature sensor 9 Nm Filling with coolant Fill with coolant up to lower edge of filler neck 1 Coolant Concentration down to 28 C Antifreeze 40 Water 60 Capacity 3 0 l 0 66 Imp gal Quantity...

Page 148: ...2 Checking thermostat Heat up thermostat in water bath Check start of opening and fully open setting Opening temperature Start of opening 85 C Fully open 105 C Install in the reverse order of removal...

Page 149: ...wling Remove air line 1 Release connections 2 3 4 of the coolant hos es Disconnect plug connection 5 for fan motor Release hose connection 6 and mounting 7 for radiator Install in the reverse order of...

Page 150: ...nd installing fan Remove radiator Remove rubber ring 1 and spacer bush 2 Release retaining bolts 3 4 Install in the reverse order of removal LT170070 4 1 3 2 Downloaded from www Manualslib com manuals...

Page 151: ...ove radiator in order to release connections on coolant filler neck 1 L Note Before screwing back in clean the thread of micro encapsulated screw 2 and secure it with Loctite 243 X Tightening torques...

Page 152: ...cap Pressure relief valve opens at 1 5 bar 21 756 psi Checking coolant system for leaks Screw pump BMW No 17 0 500 with adapter and screw coupling to filler neck Apply pressure to cooling system pres...

Page 153: ...yes Repair renew water pump Fan motor does not switch on no Check fuse F7 Is fuse defective yes Renew fuse no Check fan relay Is fan relay defective yes Replace fan relay no Check power circuit Does c...

Page 154: ...17 12 berm iger K hlmittelverlust no Check coolant circuit Has coolant circuit a break yes Repair break Downloaded from www Manualslib com manuals search engine...

Page 155: ...18 1 Contents Page 18 Removing and installing exhaust system 3 Removing and installing oxygen sensor 4 18 Exhaust system Downloaded from www Manualslib com manuals search engine...

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Page 157: ...g connection for oxygen sensor L Note Use new sealing rings 4 during installation X Tightening torques Exhaust system to cylinder head 21 Nm Front silencer muffler 12 Nm Exhaust system holder to footr...

Page 158: ...ootrest plate Unscrew oxygen sensor at hexagon L Note Before installing coat thread of oxygen sensor with Optimoly TA eCaution Read out Motronic defect code memory after test run X Tightening torque O...

Page 159: ...lutch housing 8 Installing clutch 9 Adjusting clutch clearance 11 Removing and installing clutch thrust bearing 12 Removing and installing clutch control rod 13 Removing and installing clutch release...

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Page 161: ...0866 1 0 039379 Total thickness of driving disc disc and lining mm in 5 3 0 20866 0 25 0 00984 Minimum thickness of driving disc mm in 4 5 0 177165 Clutch clearance at handlebar lever mm in 4 0 1 5748...

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Page 163: ...move holder for demodulators Release bottom retaining bolts 1 holding trans mission Re install main stand without switch for electric side support Remove transmission together with the com plete rear...

Page 164: ...21 6 Release housing cover 2 Remove clutch disc 3 pressure plate 4 diaphragm ring 5 and wire ring 6 LT210060 6 5 4 2 3 1 Downloaded from www Manualslib com manuals search engine...

Page 165: ...to and fro until O ring 4 is visible Cut through O ring Pull off clutch housing L Note Do not lose thrust washer 5 e Caution If clutch housing is difficult to move use three point puller BMW No 33 1 8...

Page 166: ...h housing in the correct position Install thrust ring 4 with new O ring 3 Screw on hexagon nut 5 eCaution The hexagon nut must be renewed every time it is removed X Tightening torques 1 Tighten hexago...

Page 167: ...all diaphragm spring 2 with the convex curve facing towards the pressure plate 3 Fit wire ring 1 and diaphragm spring 2 in clutch housing Fit pressure plate 3 driving disc 4 and housing cover 5 in clu...

Page 168: ...ing centring pin 3 Evenly tighten retaining bolts 4 crosswise Remove centring fixture X Tightening torque Housing cover 19 Nm Screw guide pin BMW No 23 1 820 in fitted sleeve of intermediate flange L...

Page 169: ...h BMW No 21 3 610 release locknut 6 of adjusting screw 7 on clutch release lever Unscrew adjusting screw by one to two turns then screw in until pressure point can be felt Lock adjusting screw with lo...

Page 170: ...aiter Remove gaiter 3 with spring 4 Remove thrust bearing 5 with pointed nose pliers Install in the reverse order of removal eCaution ABS rear wheel Check and if necessary adjust the sensor clear ance...

Page 171: ...n trol rod Remove rear wheel Remove exhaust system Remove clutch thrust bearing Remove clutch control rod 1 by pulling to the rear Install in the reverse order of removal LT210110 1 Downloaded from ww...

Page 172: ...ing pin 1 by pulling out to left Remove clutch release lever 2 Install in the reverse order of removal L Note Check clutch clearance and adjust if necessary X Tightening torques Exhaust to cylinder he...

Page 173: ...utch lining worn yes Renew clutch disc Clutch slips no Check clutch adjustment Is clutch adjustment incorrect yes Perform basic setting no Check clutch disc Is clutch disc damaged worn yes Renew clutc...

Page 174: ...16 Clutch operation difficult Clutch too harsh no Check output shaft lubrication Is output shaft not lubricated yes Lubricate with Optimoly MP 3 Downloaded from www Manualslib com manuals search engi...

Page 175: ...ling locking lever 10 Removing gear selector drum 11 Removing gearshift forks 11 Removing transmission shafts 12 Removing pawl 12 Removing selector shaft 13 Removing segment 13 Removing and installing...

Page 176: ...Installing gearshift forks 20 Measuring distances between transmission shafts 21 Measuring bearing distance of shafts 21 Measuring transmission cover 22 Installing transmission cover 24 Installing tra...

Page 177: ...r 5th gear 4 50 2 96 2 30 1 88 1 61 Oil grade above 5 C below 5 C all year round Brand name hypoid gear oil API class GL 5 SAE 90 SAE 80 SAE 80 W 90 Capacity l Imp pt 0 8 1 408 Axial clearance interme...

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Page 179: ...over panel with coolant level equalising tank Remove Motronic control unit Remove battery ABS I Remove control unit ABS I Detach pressure modulators from holder and secure to rear section of frame ABS...

Page 180: ...23 6 Removing starter Release positive and negative lead at starter Release mounting Pull out starter LT230410 Downloaded from www Manualslib com manuals search engine...

Page 181: ...to the oil sump and slightly raise engine Release mounting for main stand eCaution The retaining bolts are micro encapsulated and can therefore not be reused Cut through cable clip on main stand LT23...

Page 182: ...23 1 820 in holes with fitted sleeve long pin on right hand side Slowly pull off gearbox eCaution Hold gearbox at installation height until the control rod can be seen completely otherwise it can easi...

Page 183: ...A BMW No 23 1 600 to assembly stand Engage neutral Release idle lock 1 Remove coil 2 and ball 4 Release screws 3 Heat bearing seat in transmission cover to 100 C Evenly press off transmission cover at...

Page 184: ...on input shaft Drive out shaft sealing ring with drift from the in side Fit new sealing ring with drift BMW No 23 1 770 and handle BMW No 00 5 500 L Note If the coefficient of friction of the input s...

Page 185: ...shaft by approx 45 Turn gearshift forks towards the outside until guide pins are free Remove gear selector drum 3 L Note Note sleeves on guide pins Removing gearshift forks 1 Gearshift fork 1st and 2...

Page 186: ...input shaft 3 Removing pawl Using drift drive out vent arrow from the inside Remove retaining ring 1 on guide rod Pull out guide rod Remove pawl retaining bracket together with pawl Remove retaining r...

Page 187: ...Caution Secure setscrew with Loctite 242 screw and hole must be clean and free of grease X Tightening torque Setscrew selector shaft 17 Nm Drive in transmission case bent by 10 mm and fit cap Removing...

Page 188: ...th the aid of support BMW No 00 8 560 and internal extractor BMW No 00 8 563 Fit new bearing shell in transmission housing while still hot Drive bearing shell to bottom of seat with drift BMW No 23 1...

Page 189: ...move second taper roller bearing Assembling input shaft Fit washer 6 coil spring 5 thrust piece 4 and spur gear 3 on input shaft Using universal puller tension spur gear against coil spring until the...

Page 190: ...roller bearing as far as it will go on the retaining ring L Note There must be no clearance between the bearing and retaining ring in order to precisely determine the thickness of the spacer 00 7 500...

Page 191: ...h gear 0 20 0 40 mm 0 007874 0 01575in Set axial clearance with spacer shim rings As part of the overall dimension the spacer ring is fitted between the spur gear for 1st and 4th gear Removing ball be...

Page 192: ...ing bush 4 Heat bearing bush 6 to 80 C Carefully remove spur gear for 4th gear 8 spacer shim ring 7 and bearing bush 6 Remove retaining ring 9 Remove serrated washer 10 Remove spur gear for 2nd gear 1...

Page 193: ...spacer shim ring Heat ball bearing up to 80 C and slide on up to the spacer shim ring Turn output shaft in vice splines facing down ward Fit spur gear for 4th gear 1 claws facing down ward Fit spacer...

Page 194: ...earshift forks Fit gearshift fork for 5th gear 1 with short guide end facing upward in the bottom section of the output shaft Fit gearshift forks for 1st and 2nd gear 2 with short guide end facing dow...

Page 195: ...or the input shaft measure through the window in the measuring plate the distance from the bearing collar to the measuring plate Enter all measurements in a table see example L Note The dimension for...

Page 196: ...ring inner face to parting sur face of transmission cover Enter all measurements in a table see example Dab Cover dimension output shaft Dzw Cover dimension intermediate shaft Dan Cover dimension inpu...

Page 197: ...t Input shaft an H 30 00 1 1811 in 30 00 1 1811 in 30 00 1 1811 in M measure 5 45 0 2146 in 6 05 0 2382 in 20 10 0 7913 in G 35 45 1 3957 in 36 05 1 4193 in 9 90 0 3897 in D measure 36 40 1 4331 in 36...

Page 198: ...ss back locking lever in direction shown by arrow Carefully fit cover on the housing Screw in screws holding transmission cover and firmly tighten X Tightening torque Retaining screws for cover 9 Nm T...

Page 199: ...eeve in the intermediate flange Screw in long pin on right hand side Fit slip sleeve BMW No 23 1 800 on control rod Fit control rod from front through the input shaft Place transmission on guide pins...

Page 200: ...electric side support on bear ing mount secure lead with cable clip 2 Note spacer sleeves 3 Coat bolts with Loctite 243 screw in and firmly tighten X Tightening torque Bearing mount to transmission 4...

Page 201: ...ative leads X Tightening torque Positive lead 5 Nm Starter to transmission 9 Nm ABS I Install support bracket for pressure mod ulators L Note Note arrangement of wiring loom LT230410 LT230510 Download...

Page 202: ...n of fairing X Tightening torques Fixed swinging arm bearing at geabox 8 Nm Fixed swinging arm bearing journal free bearing 7 5 Nm Locknut free bearing 41 Nm Bearing pin of fixed bearing 150 Nm clean...

Page 203: ...oller bearing 6 Removing and installing bearing outer race in steering head 7 Removing bearing outer race 7 Installing bearing outer race 7 Measuring telescopic fork 8 Checking lower fork bridge 8 Che...

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Page 205: ...ork tube in slider tube mm in 0 05 0 209 0 00197 0 00823 Maximum permissible runout of fixed fork tube mm in 0 15 0 0059 Length of fork support spring mm in 425 16 732 Coil wire diameter of fork suppo...

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Page 207: ...telescopic fork without fork bridge Release clamping screws 1 2 pull down telescopic fork and remove Removing telescopic fork with fork bridge Removing upper fork bridge Release hexagon nut 4 Release...

Page 208: ...ill go L Note Dust ring must have no clearance Grease bearing with for example Shell Retinax A Removing and installing upper taper roller bearing Removing taper roller bearing Using a drift knock out...

Page 209: ...ring outer race belong together always fit together Installing bearing outer race With the aid of the spindle of the frame test gauge BMW No 46 5 604 605 in conjunction with the thrust piece BMW No 31...

Page 210: ...Install two new fixed tubes with test length A in lower fork bridge 1 Test installation length A 210 mm 8 268 in Place two test straight edges BMW No 31 4 620 over the upper and lower ends of the fix...

Page 211: ...with jaw guards Install upper fork bridge L Note Fork bridge must slide smoothly on to fixed tubes Check parallel alignment of fixed tubes using slide gauge Check flush alignment of steering tube wit...

Page 212: ...th ends of stanchion in V blocks Slowly turn fixed tube while checking dial gauge eCaution Distorted fixed tubes must not be straightened out Permissible runout 0 15 mm 0 0059 in LT310100 Downloaded f...

Page 213: ...g for brake caliper vertically in vice with jaw guards Using a blunt knife lever out dust sleeve 1 from the outside Using a small screwdriver lever out retaining ring 2 for sealing ring Fit support ri...

Page 214: ...be using clamping fixture BMW No 31 5 550 and clamping insert BMW No 31 5 553 With the aid of a screwdriver push apart retain ers 2 on the piston rod Remove perforated disc 3 and spacer 4 Remove dampe...

Page 215: ...part plain bush 8 on the fixed tube arrows and remove Slightly preform new plain bush in order to achieve an optimum fit on the fixed tube LT310160 LT310170 Downloaded from www Manualslib com manuals...

Page 216: ...be 8 in vice with jaw guards Slide complete damper cartridge into the fixed tube Loosely screw base screw fitting arrow into damper cartridge With the aid of clamping fixture BMW No 31 5 550 and clamp...

Page 217: ...disc 3 smooth side facing down ward Fit retainers 2 and relieve clamping fixture Screw in screw plug renew seal if necessary X Tightening torque Base screw fitting 20 Nm LT310150 4 3 2 Downloaded from...

Page 218: ...ed tube and release L Note Prior to assembly lightly coat radial sealing ring with tyre fitting paste Installation location Large groove at bottom label ling facing up Fit retaining ring 4 in groove a...

Page 219: ...elescopic fork from below into steering head Install setting ring 1 heat bearing 80 C Install upper fork bridge 2 Screw in locking tube 3 L Note Do not firmly tighten clamping screws of the upper fork...

Page 220: ...que Setting torque Hexagon nut 12 Nm New bearing Pretighten hexagon nut 25 Nm Move steering several times from lock to lock loosen hexagon nut retighten 12 Nm Mark new position of setting ring on adhe...

Page 221: ...BS sensor line 2 and connect Install fuel tank Install front wheel Install brake caliper L Note Compress telescopic fork several times then firmly tighten fork stabiliser crosswise X Tightening torque...

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Page 223: ...ving and installing right handlebar fitting 7 Removing and installing handlebar 8 Removing and installing handlebar clamping blocks 9 Removing and installing accelerator cable 10 Removing and installi...

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Page 225: ...2 Technical Data K 1100 LT K 1100 RS Steering anglel 2 x 34 Steering tube mm in 22 0 86614 Handlebar width with weights mm in 765 30 11805 700 27 559 Downloaded from www Manualslib com manuals search...

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Page 227: ...for clutch switch 2 Detach cold start operating cable at lever 3 Detach clutch cable 4 at clutch release lever then at handlebar lever Removing and installing handlebar weight Release countersunk scr...

Page 228: ...all in the reverse order of removal L Note Bond rubber grip with Loctite 454 on handlebar X Tightening torque Clamping screw handlebar fitting 5 Nm Settings Clutch play at handlebar lever 4 0 5 mm 0 1...

Page 229: ...amping screw 8 from fitting housing Remove fitting Cut through rubber grip and remove Install in the reverse order of removal eCaution Top up brake fluid vent system L Note Turn connection piece 3 of...

Page 230: ...1 Disconnect plug connections for switches Remove left and right handlebar fittings Release top sections of clamping block 2 Install in the reverse order of removal X Tightening torque Clamping screw...

Page 231: ...ng blocks Remove stop plate 3 Remove clamping blocks 4 Drive out handlebar mounting with drift Install in the reverse order of removal X Tightening torque Clamping block 16 Nm LT320070 4 3 Downloaded...

Page 232: ...disc on throttle stub pipe 2 and de tach cable Install in the reverse order of removal L Note When installing first attach cable at cam disc Fit ca ble without kinks Adjust cable play at adjusting sc...

Page 233: ...ing cable Install in the reverse order of removal L Note Ensure the operating cable is fitted correctly with no kinks Adjust cable after fitting Settings Play at handlebar lever 4 0 5 mm 0 15748 0 019...

Page 234: ...justing screw 4 and unscrew adjusting screw Detach nipple 5 Remove cable by pulling from below Install in the reverse order of removal L Note Fit cable without kinks Check setting of start speed incre...

Page 235: ...gon nut 12 Nm Setting torque for new bearing Pretighten hexagon nut to 25 Nm Move steering from lock to lock several times loosen hexagon nut and retighten 12 Nm Mark new position of setting ring on a...

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Page 237: ...e bearing in rear wheel drive 11 Removing crown wheel 12 Installing crown wheel 13 Checking adjusting tooth backlash 14 Checking contact pattern 15 Shimming housing cover 16 Installing housing cover 1...

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Page 239: ...mp pt 0 25 0 44 0 23 0 4048 Viscosity class at outside temperature above 5 C below 5 C all year SAE 90 SAE 80 SAE 80 W 90 Drive shaft Arrangement Encapsulated in the one arm swinging fork BMW PARALEVE...

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Page 241: ...en strut on rear wheel drive 3 Release spring strut at rear wheel drive 6 and remove from stud bolt by pulling to the side Disconnect rear wheel drive from drive shaft L Note When the rear wheel drive...

Page 242: ...nd release with 36 mm 1 4173 in socket wrench insert and reducing adapter BMW No 33 1 720 eCaution Never use a hammer to release the hexagon nut otherwise the splines can be easily damaged Remove thru...

Page 243: ...amp drive bevel gear 1 in vice with jaw guards splines facing upward Using puller BMW No 00 7 500 remove both bearings at the same time Remove thrust bearing 4 inner race 5 bearing cage 6 and outer ra...

Page 244: ...ring with the aid of inner extractor BMW No 00 8 573 and sup port BMW No 00 8 570 Installing needle bearing for drive bevel gear Heat bearing seat of needle bearing to 100 C Press in needle bearing wi...

Page 245: ...ar as it will go Slide outer bearing race 2 together with cylin der roller cage 3 onto inner race 4 Heat ball bearing 5 to 100 C and fit on drive bevel gear 1 as far as it will go Allow drive bevel ge...

Page 246: ...BMW No 33 1 700 Fit thrust ring 4 L Note Ensure the sealing lip of the shaft sealing ring is fit ted correctly at the thrust ring Coat hexagon nut 5 with Loctite 270 thread turns free of grease and fi...

Page 247: ...emove needle bearing using inner extractor 21 4 BMW No 00 8 573 and support 22 1 BMW No 00 8 572 Heat housing neck to 120 C Press in needle bearing with inner race on drift BMW No 36 3 700 RT33090 00...

Page 248: ...ve Drive shaft sealing ring 4 out of housing cover using drift Clamp ring gear in vice with jaw guards Fit pressure piece arrow BMW No 33 1 307 Using puller BMW No 33 1 830 remove deep groove ball bea...

Page 249: ...t outer race is correctly seated by light blows L Note The tooth backlash must be checked and adjusted if necessary if new parts have been installed e g the taper roller bearing Fit existing spacer ri...

Page 250: ...he palm of the hand press crown wheel into housing and check gear backlash by turning backward and forward L Note Check the backlash at three points offset by 120 turn bevel gear with crown wheel Take...

Page 251: ...hand and turn forward and backward several times If the correct spacer ring is installed the no load contact pattern as shown above should be ob tained L Note The contact pattern is in the centre of...

Page 252: ...acer ring and fit in position Preload 0 05 0 1 mm 0 00197 0 003937 in Installing housing cover Drive in sealing ring using drift BMW No 33 1 860 and handle BMW No 00 5 500 Install O ring lightly oiled...

Page 253: ...gainst the end faces of the needles X Tightening torque Bearing pin of fixed bearing 150 Nm clean thread Loctite 2701 Screw in the bearing pin of the loose bearing 3 with Loctite 2701 X Tightening tor...

Page 254: ...oil only up to the lower edge of the thread in the filler aperture Install the brake disc in the previously marked position X Tightening torque Brake disc to rear wheel drive 21 Nm Install the rear wh...

Page 255: ...ining bolt and remove swing ing arm bearing while turning backward and for ward Removing and installing taper roller bearing Remove taper roller bearing with support BMW No 00 8 572 and internal extra...

Page 256: ...nder lay if necessary Checking universal joint for wear Determine axial and radial play by shifting axially and turning radially Removing retaining ring Lever out retaining ring in universal joint usi...

Page 257: ...pin of loose bearing with Optimoly TA install firmly tighten and secure locknut X Tightening torques Bearing pin of loose bearing clean thread Loctite 270 7 Nm Locknut 41 Nm Installing footrest plate...

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Page 259: ...ont brake line 12 Removing upper brake line 12 Removing lower brake line 12 Removing and installing ABS brake line from front pressure modulator 13 Removing and installing handbrake cylinder 14 Bleedi...

Page 260: ...ing and assembling rear brake caliper 23 Dismantling rear brake caliper 23 Assembling rear brake caliper 23 Removing and installing rear brake disc 24 Removing and installing rear ABS sensor 25 Measur...

Page 261: ...ed at max distance point mm in 0 50 0 55 0 0197 0 0216 Up to 1996 MY 0 45 0 55 0 0177 0 0216 From 1997 MY Rear wheel Brake disc mm in 285 11 22 Brake disc thickness mm in 5 0 2 0 197 0 00787 Minimum t...

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Page 263: ...e caliper from brake disc eCaution Brake pads must not be damaged Release brake line at brake caliper and close off eCaution Ensure brake fluid does not come in contact with painted vehicle parts brak...

Page 264: ...ed screw X Tightening torque Bleed screw at brake caliper front 14 Nm Hold a cloth over the brake caliper Carefully press out brake pistons 2 using a compressed air gun at the brake line connection eC...

Page 265: ...per pistons 2 with brake fluid and insert eCaution Do not tilt the brake pistons when installing Using piston resetting tool 5 BMW No 34 1 500 press the pistons fully back Insert brake pads and secure...

Page 266: ...ds eCaution Do not allow brake pads to wear down below the minimum thickness arrow Replace pads only as complete set Minimum brake pad thickness Thickness on carrier plate 1 5 mm Install in the revers...

Page 267: ...r 2 with brake disc Removing and installing ABS pulse wheel Release pulse wheel on brake disc carrier XTightening torque Pulse wheel 4 Nm L Note Before installing the pulse wheel clean the micro encap...

Page 268: ...0 Install in the reverse order of removal L Note Carefully install the sensor line arrow note position and number of cable clips and ensure tyre can turn smoothly Check sensor spacing where the gap is...

Page 269: ...t the sensor spacing with spacer plates at the point with the least pointer deflection Remove and install sensor using Torx socket BMW No 34 2 500 Sensor spacing front Up to 1996 MY 0 50 0 55 mm 0 019...

Page 270: ...ling rings of brake lines eCaution Ensure brake fluid does not come in contact with painted parts of the vehicle brake fluid destroys the paintwork Removing lower brake line Remove rear section of mud...

Page 271: ...ew connections 1 2 Release connections at pressure modulator 3 Remove both lines together Release spacer 4 and replace defective line Install the reverse order of removal XTightening torques Screw con...

Page 272: ...e stop screw 4 eCaution Piston is under spring loading Relieve load on piston and remove together with spring 5 Check brake cylinder piston and sealing rings Install in the reverse order of removal L...

Page 273: ...e piston fully back Take out the piston resetting tool insert spacer BMW No 34 1 520 and move it up to the brake disc Press the piston back in the second brake cali per but do not remove the piston re...

Page 274: ...ing L Note When adding brake fluid note the thickness of the brake pads Add brake fluid up to the MAX mark if the pads are new Add brake fluide L Note When checking front brake fluid level the brake f...

Page 275: ...ssembly and the brake lines Detach brake lines 2 3 at the pressure modula tor and seal cover them eCaution Escaping brake fluid will damage painted surfaces Detach the pressure modulator at silentbloc...

Page 276: ...it eCaution To avoid leaks caused by particles of dirt penetrat ing the brake system clean the hydraulic pump as sembly and the brake lines before detaching them If appropriate cover or seal the line...

Page 277: ...Caution Use new self locking nuts XTightening torques Battery M5 3 5 Nm Battery M5 3 Nm Fit a new cover eCaution When sliding on make sure that all cables are posi tioned correctly in their guides Alw...

Page 278: ...BS relay with FAG logo in the direction of the retaining hook Tighten the screws at the relay base Push the relay base into the relay housing at the same time pressing both engine wires into the left...

Page 279: ...te The crimp side must face toward the screw head eCaution The same Torx screws must be used because of their self locking acition When inserting make sure that the thread already present in the sheet...

Page 280: ...ck ABS sensor spacing if necessary readjust with spacer plates Sensor spacing rear Up to 1996 MY 0 60 0 65 mm 0 0236 0 0256 in From 1997 MY on 0 45 0 55 mm 0 0177 0 0216 in Removing and installing rea...

Page 281: ...Hold a cloth over the brake caliper piston Carefully press out brake piston 6 with a com pressed air gun applied to the connecting bore work at low air pressure Remove sealing rings 5 from left right...

Page 282: ...l is not changed Install in the reverse order of removal L Note Screw in retaining screws with Loctite 270 Check ABS sensor spacing if necessary adjust with spacer plates XTightening torque Brake disc...

Page 283: ...line Install in the reverse order of removal eCaution Check sensor spacing where the gap is greatest if necessary adjust with spacer plates 3 Carefully lay sensor line Sensor gap Up to 1996 model year...

Page 284: ...No 34 2 510 on pulse wheel Set dial gauge to zero Measure vertical runout over the entire circum ference Mark the point with the least vertical runout with oil paint Adjust the sensor spacing at this...

Page 285: ...t master brake cylinder 2 Remove footrest plate Release master brake cylinder 2 Note spacer sleeve 3 spring is under pressure Open clip 4 on the supply line detach line Install in the reverse order of...

Page 286: ...le way inwards Press out stop screw 3 Pull out piston with spring 4 Loosen spring from ring groove Check piston and sealing rings 5 for damage Install in the reverse order of removal L Note Lightly co...

Page 287: ...lin der Release mounting 2 for brake pedal eCaution Spring is under tension Remove bearing bush 3 Install in the reverse order of removal L Note Grease bearing bush with Shell Retinax A or similar XTi...

Page 288: ...Distance A 0 2 mm 0 00787 in Turn adjusting screw 3 on master brake cylinder until slight resistance is felt when the foot brake pedal is operated Firmly tighten locknut and remove feeler gauge XTigh...

Page 289: ...brake system yes Bleed brake system no Check brake system Is brake system leaking yes Repair leaks Brake pedal difficult to move hard no Check brake pads Are brake pads glazen worn yes Renew brake pad...

Page 290: ...aged yes Renew brake pads no Check brake system Is there air in brake system yes Bleed brake system Brakes squeak no Check brake pads Are brake pads dirty yes renew brake pads no Check brake discs Is...

Page 291: ...ic system operation yes Rectify defect no Check brake piston Are brake pistons jammed yes Change break piston master brake cylinder no Check brake discs wheels Is lateral runout too large yes Replace...

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Page 293: ...d right bearings 6 Removing and installing rear wheel 7 Removing rear wheel 7 Installing rear wheel 7 Static balancing of front and rear wheels 8 Static balancing of front wheel 8 Static balancing of...

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Page 295: ...ess rear 140 80 VB 17 Tubeless 160 60 VB 18 Tubeless Tyre pressures cold Solo front bar psi 2 2 31 3 Solo rear bar psi 2 5 35 6 Two up front bar psi 2 5 35 6 Two up rear bar psi 2 9 41 2 Wheel bearing...

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Page 297: ...Pull out the quick release axle noting the pres ence of spacers 4 5 Remove front wheel L Note Do not apply the brake when the front wheel is re moved Installation in the reverse order of work Check AB...

Page 298: ...rt BMW No 00 8 573 Removing right bearing The right bearing has no circlip Place the protective ring in position with the open side against the wheel hub Pull the bearing out in the same way as for th...

Page 299: ...all wheel studs handtight eCaution Only use wheel studs with length code 60 LT360040 1 2 2 3 60 Tighten the outer wheel studs in a crosswise pat tern to the preload torque Tighten the central stud to...

Page 300: ...mm 0 018 0 022 in LT360050 3 2 1 Static balancing of rear wheel Remove the wheel Attach mounting device 2 BMW No 36 3 613 to the centering collar side with the wheel studs Install balancing shaft 1 BM...

Page 301: ...3 mm 0 012 in Checking rear wheel for runout Attach the rear wheel without tyre to mounting device 2 BMW No 36 3 613 and secure on the centering collar side with wheel studs Install balancing shaft 1...

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Page 303: ...e 10 Removing lever 11 Removing guide bush in lever 11 Removing sliding piece 11 Removing and installing upper section of fairing 12 Removing and installing fairing RS 13 Removing and installing lower...

Page 304: ...head 20 Removing and installing seat lock 21 Removing and installing handle 21 Installing frame 22 Removing and installing main centre stand 23 Line arrangement for side stand 23 Disassembling and ass...

Page 305: ...ight frame tube Maximum width over mirrors mm in 915 36 02 802 31 57 Seat height without load mm in 810 31 89 800 31 5 Wheelbase without load mm in 1565 61 6 Unladen weight kg lb 290 639 45 268 590 9...

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Page 307: ...cover 3 Remove rear section of mudguard 4 LT Detach Velcro connections 5 Remove front section of mudguard 6 Install in the reverse order of removal L Note LT Position of Velcro connection 6 LT460010 4...

Page 308: ...g and installing rear sec tion Remove dualseat Remove combined tail light unit Release securing screw 1 Install in the reverse order of removal LT460030 1 Downloaded from www Manualslib com manuals se...

Page 309: ...7 Removing and installing rear mudguard 1 Rubber sleeves on gearbox 2 Bracket 3 Sheet metal nuts 4 Licence plate support bracket LT490040 3 4 2 1 Downloaded from www Manualslib com manuals search engi...

Page 310: ...e storage box 2 Remove cover 3 Remove side section 4 Install in the reverse order of removal Removing radiator cowling Remove radiator cowling 5 Remove cover 6 1 Frame 2 Grille 3 Cowling 4 Cover LT460...

Page 311: ...with motor Remove inner cover Release securing screws 2 Detach water ducts 3 at the top nipple Disconnect electrical plug connection Remove windshield with motor Install in the reverse order of remov...

Page 312: ...Removing plate Remove actuator motor Release mounting element 1 for plate 2 Install in the reverse order of removal L Note The retaining screws are micro encapsulated and therefore cannot be re used...

Page 313: ...fore in serting Spray guide rod with silicone spray Removing guide bush in lever Remove lever Loosen locknut 1 unscrew pressure screw 2 L Note Installation Only tighten pressure screw such that the gu...

Page 314: ...airing and radiator cowling Remove cover 1 Remove complete windshield 2 Disconnect plug connections for headlight and turn indicators Remove upper section of fairing 3 Install in the reverse order of...

Page 315: ...val Removing and installing side section of fairing Side section of fairing 2 Remove lower section of fairing 1 Remove knee pad 3 Release securing screw on upper section 4 on radiator cowling 5 and on...

Page 316: ...re 4 Disconnect plug connection for turn signal indi cator and headlamp Release securing screw 5 on frame and 6 at fairing support bracket Remove fairing by pulling forward Install in the reverse orde...

Page 317: ...1 Disconnect cable clips for wiring loom Release securing screw 2 Install in the reverse order of removal Arrangement of cable clips LT Arrangement of cable clips RS X Tightening torque Fairing suppor...

Page 318: ...o that the measuring level is as near as possible to the centre of the wheel It must be possible to smoothly slide the gauge to wards the motorcycle Adjust limit stops arrows so that they only rest on...

Page 319: ...cance of measurement result Negative sign Track offset to left Positive sign Track offset to right Formula S Fixed value A length of measuring stops A 50 0 mm half of rear wheel rim width 44 5 mm Meas...

Page 320: ...ring screw at the gear box check that the screws can be screwed in again easily If this is not possible the frame is in all probability distorted Fit adapter BMW No 46 5 606 instead of se curing screw...

Page 321: ...in order when the tips of the measuring pins on the left and right are located in approximate ly the same position within the grid circle Max deviation Left to right 2 mm 0 0787 in 2 boxes eCaution T...

Page 322: ...trut Release frame at engine and lift off Remove frame wiring loom with central electrics box ABS II Remove front brake lines Dismantle assemble frame Disassembling and assembling frame Remove all rub...

Page 323: ...Lever out spring using screwdriver remove spring seat Detach handle Remove spring with second spring seat Install in the reverse order of removal L Note Grease the pivot point a little before install...

Page 324: ...c fork and adjust steering Setting torque Hexagon nut 12 Nm New bearing adjustement procedure Pre tighten hexagon nut to 25 Nm Move steering from stop to stop several times loosen hexagon nuts retight...

Page 325: ...ease retaining screws 1 and detach main stand together with side stand Install in the reverse order of removal L Note The retaining screws are micro encapsulated and can therefore not be re used Clean...

Page 326: ...sembling side stand Detach switch 1 Detach tension springs 2 Remove bracket 3 with spring Remove operating hook 4 Remove leg spring 5 Release securing screw 6 of side stand LT460340 1 2 6 4 5 3 Downlo...

Page 327: ...Do not grease operating hook and bracket increased dirt accumulation Attach tension springs 4 Prior to installation check condition of switch contact spring must not be bent In no load condition ther...

Page 328: ...n left right Remove bearing block 5 Loosen grease nipple 6 Assemble in the reverse order of disassembly L Note Screws 2 are micro encapsulated and must there fore not be re used Clean threades and hol...

Page 329: ...b 50 mm 1 97 in Fold in side stand and start engine Slowly fold out side stand the engine must cut out in the area of dimension b If the engine does not cut out check or replace the switch eCaution B...

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Page 331: ...g lock 3 Removing and installing lock cylinder for fuel tank 4 Removing lock cylinder 4 Installing locking cylinder 4 Removing lock cylinder with broken key 4 Removing and installing dualseat lock 5 5...

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Page 333: ...Fit drilling bushing 1 BMW No 51 0 500 in hole ith 4 mm drill drill shear bolt to a minimum depth of 10 mm With an 8 mm drill drill shear bolt to a minimum depth of 8 mm Remove lock barrel from below...

Page 334: ...er Grease lock cylinder with Shell Retinax A Fit lock cylinder with key in mounting groove arrow Press down lock cylinder and turn key in clock wise direction catch engages Install housing Removing lo...

Page 335: ...51 5 Removing and installing dualseat lock 5 Saucer head screw 6 Phillip head screw 7 Stop nut LT510040 2 1 1 3 Downloaded from www Manualslib com manuals search engine...

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Page 337: ...ol unit 6 Removing and installing battery 7 Relay locations central electrical unit 8 Locations and connections ABS wiring loom 9 Locations frame wiring loom 10 View from left 10 Wiring arrangement fa...

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Page 339: ...61 3 61 Technical Data K 1100 LT K 1100 RS Battery Ah 19 Downloaded from www Manualslib com manuals search engine...

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Page 341: ...ignition disconnect and insulate earth ground lead Open dualseat Press catch 1 for multi pin plug and detach plug Loosen screws 2 and remove control unit X Tightening torque Motronic control unit 5 Nm...

Page 342: ...right and remove housing 3 together with control unit Remove ABS control unit 4 from housing 5 Install in the reverse order of removal L Note Ensure that lug 6 on housing 3 is fitted correctly in the...

Page 343: ...nit ABS I Remove ABS control unit Disconnect positive lead Detach vent hose 1 Install in the reverse order of removal L Note First connect positive pole followed by negative pole Coat battery terminal...

Page 344: ...y 3 Turn indicator relay 4 ABS I ABS relay L Note With ABS II the relay is on the ABS unit See Group 34 Removing and installing ABS relay base 5 Motronic relay 6 ABS warning relay 7 Fan relay 8 Horn r...

Page 345: ...I Multi pin plug ABS control unit 2 ABS I Plug connection front pressure modulator 3 ABS I Plug connection rear pressure modulator 4 Plug connection front sensor 5 Plug connection rear sensor L Note A...

Page 346: ...ht connection 6 Left multfunction switch connection 7 Alternator connection 8 Battery connection positive 9 Starter connection 10 Socket connection 11 Choke line 12 Plug connection engine wiring loom...

Page 347: ...n switch plug connection 10 Inductive pulse generator plug connection 11 Electric side stand switch connection L Note Arrange wiring loom without kinks and chafing points first install central electri...

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Page 349: ...moving and installing p c board 8 Removing and installing quartz clock 8 Removing and installing frame for indicator lamps 8 Removing and installing p c board for fuel gauge 8 Removing and installing...

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Page 351: ...Technical Data K 1100 LT K 1100 RS Instrument cluster Turn signal indicator lamps 12 V 4 W T 8 4 Other indicator lamps instrument lights 12 V 3 W 10 3 Downloaded from www Manualslib com manuals search...

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Page 353: ...elease screw 1 and disconnect central plug connector Release screws 2 remove instrument cluster and counterweight 3 Rubber buffers 4 remain in instrument support bracket Install in the reverse order o...

Page 354: ...1 and disconnect central plug connector Release screws 2 and remove instrument clus ter Housing base 3 and cable cover 4 remain on the frame Install in the reverse order of removal LT620020 1 4 3 2 Do...

Page 355: ...ng 4 Assemble in the reverse order of disassembly L Note Ensure gasket is fitted in correct position Removing and installing indicator lamp Grip indicator lamp 1 diagonally with relay pli ers BMW No 6...

Page 356: ...oks towards the out side in the sequence 2 3 and 4 5 Remove quartz clock 6 by pulling upward Install in the reverse order of removal Removing and installing frame for indicator lamps Carefully press h...

Page 357: ...ase screws 1 Lift out revolution counter 2 Removing and installing speedometer Release screws 3 Completely pull out reset button 4 to the right Lift out speedometer 5 LT620090 1 2 LT620100 5 4 3 Downl...

Page 358: ...i cator Remove tachometer Carefully pull pointer 1 off the spindle Release screws 2 Remove dial face 3 Release screws 4 Lift out p c board 5 L Note Note position of spacer 6 LT620110 2 4 1 3 5 6 Downl...

Page 359: ...63 1 Contents Page 63 Technical Data 3 Disassembling and assembling headlights 5 Adjusting headlights 6 63 Lights Downloaded from www Manualslib com manuals search engine...

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Page 361: ...ctangular headlight with two stage manual range adjustment Bulbs High beam low beam H 4 halogen bulb 55 60 W asymmetric Parking light 12 V 4 W Rear light 12 V 10 W Brake light 12 V 21 W Turn signal li...

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Page 363: ...the reflector or bulbs with bare hands Individual parts 1 Glass 2 Gasket 3 Reflector 4 Reflector 5 Retaining spring 6 Bulb 7 Bulb socket 8 Retaining spring 9 Cover 10 Adjusting screw 11 Lamp socket 1...

Page 364: ...lever 1 in top position Correct headlight range with adjusting screw 2 Turning counterclockwise shorter Turning clockwise further Adjust side angle with knurled screw 3 LT630020 2 3 1 Downloaded from...

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